AU2021201069A1

AU2021201069A1 - A Construction System and Method of Use Thereof

Info

Publication number: AU2021201069A1
Application number: AU2021201069A
Authority: AU
Inventors: Norman Gordon Pask
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-11-08
Filing date: 2021-02-18
Publication date: 2021-06-24
Anticipated expiration: 2040-11-05
Also published as: AU2020264333B2; AU2021201069B2; AU2020264333A1

Abstract

The present invention concerns a construction system for multi-storey buildings including vertical and horizontal preformed construction elements and method of construction using the same. In one form, the system includes a plurality of vertical preformed construction elements configured to define one or more walls and/or columns of the building and a plurality of horizontal preformed construction elements configured to be mounted atop the plurality of vertical preformed construction elements to define a floor of the building. Each element includes a cementitious body, one or more hollow sections at least partially embedded within the cementitious body and and one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element, the one or more spacing members being configured to connected at least one panel member thereto. The construction elements are configured to be coupled and/or joined relative to one another to form at least one storey of building. Further, when the construction elements are coupled orjoined relative to one another, the at least one panel member on each element is arranged relative to other panel members to form internal ceiling and wall surfaces of at least one room of the building.

Description

A CONSTRUCTION SYSTEM AND METHOD OF USE THEREOF TECHNICAL FIELD

[0001] The present invention relates to a construction system and method of use. In particular, the present invention relates to preformed construction elements and a method of construction using the same to erect multi-storey buildings.

BACKGROUND

[0002] Conventional building techniques often employ precast structural elements for the construction of walls, floors and the like. One of the problems associated with the use of such precast structural elements is the accurate positioning of such elements to produce a true and level wall or floor.

[0003] Another problem with using conventional precast structural elements is the time required to construct walls or floors. This is partially due to the aforementioned problem to accurately position the elements and other alignment drawbacks cause by irregularities in the precast elements. Delays in constructing a wall or floor subsequently delays higher walls and floors being constructed and/or other features of a building being installed. This results in projects falling behind schedule and costly fines being levied against those responsible, particularly in high-rise construction of multi-storey buildings.

[0004] Under conventional building practice, it is typical for the formwork, steel reinforcement and the fabrication of the structural elements to be done by one trade and the infilling between columns with steel studs, insulation, exterior sheathing/curtain walling and interior drywalling to be done by other trades. The use of multiple trades creates problems in terms of coordinating work done by the respective trades and minimising error, i.e., there is more room for error when more than one trade is responsible for interrelated tasks. In some scenarios, the coordination of work between the respective trades can often delay building construction. Again, these delays are particularly pronounced in multi-storey building construction.

[0005] Further, the use of conventional precast structural elements can be problematic in some climates, such as, e.g., cold- or wet-weather climates. For example, extensive tarping or water-proofing is required to keep the vertical elements and/or the interior of unfinished buildings warm and/or dry.

SUMMARY OF INVENTION

[0006] Embodiments of the present invention provide a system for constructing multi-storey buildings, horizontal and vertical construction elements and moulds thereof, and a method of constructing a multi-storey building, which may at least partially overcome at least one of the abovementioned problems or provide the consumer with a useful or commercial choice.

[0007] According to a first aspect of the present invention, there is provided a system of constructing a multi-storey building, said system including: a plurality of vertical preformed construction elements configured to define one or more walls and/or columns of the building, each element including a cementitious body and at least one panel member defining at least one surface of the element, each said element adapted to couple with adjacent construction elements to define the one or more walls and/or columns; and a plurality of horizontal preformed construction elements configured to be mounted atop the plurality of vertical preformed construction elements to define a floor of the building, each element including a cementitious body and at least one panel member defining a surface of the element, each said element configured to be joined with adjacent like elements in an edge to edge arrangement to define the floor, wherein said construction elements are configured to be coupled and/or joined relative to one another to form at least one storey of the multi-storey building, and wherein when the construction elements are coupled and/or joined relative to one another, the at least one panel member on each said element is arranged relative to other panel members to form internal ceiling and wall surfaces of at least one room of the multistorey building.

[0008] According to a second aspect of the present invention, there is provided a preformed construction element, said element including: a cementitious body; and at least one panel member defining at least one surface of the element.

[0009] According to a third aspect of the present invention, there is provided a preformed construction element, said element including:

a cementitious body;

one or more hollow sections at least partially embedded within the cementitious body;and

one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element, wherein the one or more spacing members are configured to allow for the connection of a panel member thereto.

[0010] According to a fourth aspect of the present invention, there is provided a system of constructing a multi-storey building, said system including: a plurality of vertical preformed construction elements configured to define one or more walls and/or columns of the building, each element including a cementitious body, one or more hollow sections at least partially embedded within the cementitious body, one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element, each said element adapted to couple with adjacent construction elements to define the one or more walls and/or columns; and wherein at least one panel member is connected to the one or more spacing members, a plurality of horizontal preformed construction elements configured to be mounted atop the plurality of vertical preformed construction elements to define a floor of the building, each element including a cementitious body and at least one panel member defining a surface of the element, each said element configured to be joined with adjacent like elements in an edge to edge arrangement to define the floor, wherein said construction elements are configured to be coupled and/or joined relative to one another to form at least one storey of the multi-storey building, and wherein when the construction elements are coupled and/or joined relative to one another, the at least one panel member on each said element is arranged relative to other panel members to form internal ceiling and wall surfaces of at least one room of the multistorey building.

[0011] Preferably, said construction element further includes at least one coupling member adapted to couple with a like coupling member provided on an adjacent construction element to couple the elements together.

[0012] Advantageously, the system and construction elements of the present invention enable a multi-storey building to be quickly and readily constructed with minimal error and by a single trade. This in part minimises delays caused interrelated tasks carried out by multiple trades. Further embodiments of the construction elements including the coupling member in part minimise delays by enabling the construction elements to be readily aligned and coupled to one another. Lastly, the construction elements of the present invention provide the means for multi-storey buildings to be constructed in a methodical, precise and rapid manner and thereby minimise the need for extensive tarping.

[0013] The preformed construction elements may be of any suitable size and shape for defining a wall, column, floor, or part thereof.

[0014] As used herein, the term "preformed" means that the construction elements have been fabricated prior to assembly. For example, the construction elements may be fabricated prior to being transported to a job or construction site. Alternatively, the construction elements may be fabricated on the job site but prior to assembly (i.e., not cast in place), preferably using a rapid set cement or concrete.

[0015] Generally, each element may be in the form of a panel having a substantially polygonal shape, preferably rectangular.

[0016] Typically, each preformed construction element may include a pair of opposed surfaces extending substantially parallel to one another, a pair of opposed side edges and a pair of opposed end edges.

[0017] In preferred embodiments, the elements may include vertical preformed construction elements configured to define one or more walls and/or columns of a multi-storey building and horizontal preformed construction elements configured to define a floor of the multi-storey building.

[0018] Each vertical preformed construction element includes a pair of opposed surfaces, a lower end edge, an opposed upper end edge and a pair of opposed side edges. The opposed surfaces may include an inward facing surface and an opposed outward facing surface. It is envisaged that, when the at least one panel member is connected to the one or more spacing members, at least one of the opposed surfaces may be at least partially formed by the at least one panel member, preferably an inward facing surface.

[0019] Likewise, each horizontal preformed construction element includes a pair of opposed surfaces, a pair of opposed end edges and a pair of opposed side edges. The opposed surfaces may include a downward facing surface and an opposed upward facing surface. Again, at least one of the opposed surfaces may be at least partially formed by the at least one panel member, preferably the downward facing surface.

[0020] Generally, the vertical preformed construction elements may be connectable with other like vertical preformed construction elements to define a wall and/or a column, preferably in an edge to edge arrangement, more preferably a side edge to side edge arrangement.

[0021] Likewise, the horizontal preformed constructions elements may be connectable with other like horizontal preformed construction elements to define a floor of the building, preferably in an edge to edge arrangement, more preferably a side edge to side edge arrangement.

[0022] In preferred embodiments, the at least one panel member of each element may extend across an entire surface of the element to facilitate the forming of ceiling and/or wall surfaces when the elements are coupled and/or joined relative to one another.

[0023] In some embodiments, panel members may be provided on more than one surface. For example, panel members may be provided on a surface and an adjacent edge of an element to define a corner in room of the building, for example.

[0024] In some embodiments in which a vertical preformed construction element may define a column, panel members may be provided at least partway about a periphery of the element, preferably on both opposed surfaces and side edges.

[0025] As indicated, each element includes a cementitious body. The cementitious body is preferably fabricated by pouring cement or concrete in a mould together with other components of the element. In some embodiments, the mould may include a casting bed and formwork. In other embodiments, the mould may be formed from just formwork.

[0026] As previously stated, the preformed construction element includes one or more hollow sections at least partially embedded within the cementitious body. It will be understood that the term "hollow section" refers to elongate tubing, and in particular elongate metal tubing. Most preferably, the hollow section may be elongate steel tubing. The hollow section may have any cross-sectional area. For instance, the hollow section may be circular, square, rectangular or the like in cross-sectional shape. The hollow section may be of any suitable length.

[0027] In some embodiments of the invention a single hollow section may be embedded within the cementitious body. More preferably, a plurality of hollow sections may be embedded within the cementitious body. In a preferred embodiment of the invention, the plurality of hollow sections is substantially identical in cross-sectional shape. In some embodiments of the invention, the plurality of hollow sections may also be substantially identical in length, width and height.

[0028] Preferably, the plurality of hollow sections is positioned substantially co-axially with one another (i.e. in an end to end arrangement), so that the hollow sections extend along at least a portion of the length of the cementitious body. More preferably, the hollow sections extend substantially the entire length of the cementitious body.

[0029] In some embodiments of the invention, the hollow sections may be provided with one or more apertures in a wall thereof. The one or more apertures may be provided such that, when forming the preformed construction element, cementitious material may flow through the one or more apertures into the interior of the hollow sections.

[0030] In some embodiments of the invention, an aperture may be provided on opposed sides of a hollow section. In this way, one or more reinforcing members (such as steel bars) may be passed through the opposed apertures and cemented into place by the cementitious material.

[0031] Generally, the body includes one or more reinforcing members at least partially embedded in the body, preferably completely embedded in the body. In some embodiments, the reinforcing member may be a U-shaped rod or bar. In other embodiments, the reinforcing member may be a reinforcing mesh.The at least one panel member may include any suitable panel configured to form an interior wall or ceiling surface. For example, the panel member may include internal cladding or plasterboard, typically the latter. In some embodiments, the plasterboard may be fire-resistant, such as, e.g., Type X or Type C gypsum panels.

[0032] The at least one panel member may be associated with the cementitious body in any suitable way. For example, the at least one panel member may be directly or indirectly bonded or fastened to the body, preferably indirectly. The panel member may be associated with the cementitious body during manufacture, or may be associated with the cementitious body in situ during the construction of the building.

[0033] In preferred embodiments, a plurality of spacing members may extend between the body and the at least one panel member, preferably at spaced intervals. Advantageously, the spacing members may define a space between the panel member and the body for the passage of cabling, piping and insulation materials.

[0034] The spacing members may be of any suitable size, shape and form to provide a space between the panel member and the body. Generally, the spacing members may each be in the form of an elongate member that transversely extends across and between the body and the panel member.

[0035] The spacing members may or may not be load-bearing, typically the former.

[0036] The spacing member may be formed from wood, plastic or metal material or materials.

[0037] In some embodiments, the spacing member may have a rectangular shape and may be of tubular or solid construction. In other embodiments, the spacing member may have a U or C-shaped profile shape.

[00381 In some embodiments, the spacing members may additionally function as studs, joists, battens or purlins.

[0039] In preferred embodiments, the spacing member may include a batten, a purlin or a hat-type batten.

[0040] Generally, the at least one panel may be fastened to the one or more spacing members, which may be fastened or bonded to the cementitious body.

[0041] The panel member, the spacing members and the cementitious body may be fastened together in any suitable way. For example, in some embodiments, the at least one panel may be fastened to the one or more spacing members, which may be fastened to the cementitious body by one or more fasteners. The one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and/or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).

[0042] In some embodiments, the panel member may be fastened to the spacing members by one or more threaded fasteners and the cementitious body may be poured in a mould at least partly about the adjoined panel member and spacing members such that the cementitious body sets and bonds with the adjoined panel member and spacing members.

[0043] In some embodiments, the element may further include sheeting extending between the spacing members and the cementitious body to prevent wetting of the at least one panel member when the body is cast. In such embodiments, the sheeting may include plastic, cardboard or paper sheeting. The sheeting may or may not be impermeable to wet cement, preferably the former. In some such embodiments, the sheeting may include waterproof or water-resistant sheeting, such as, e.g., waxed cardboard or paper sheeting.

[0044] Typically, the sheeting may be fastened to a side of the spacing members opposite the at least one panel member, preferably with one or more fasteners. Again, the one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and/or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).

[0045] In some particular embodiments, the sheeting may include cardboard that may be fastened to the spacing members with one or more threaded fasteners. The sheeting may be fastened such that a head of each fastener protrudes out from a surface of the sheeting to facilitate bonding between the cementitious body and the adjoined panel member and spacing members when wet cement cures in the mould about the protruding heads. In preferred such embodiments, a sealant or sealing member may be applied about each protruding fastener head prior to the cement being poured into the mould containing the adjoined panel member and spacing members.

[0046] In some embodiments, the vertical preformed construction elements may further include exterior sheathing pre-attached, typically along an outer surface. The exterior sheathing may include one or more cladding panels, preferably fastened to an outer surface of the element with one or more fasteners.

[0047] In preferred embodiments, each element further includes insulation and/or sound proofing material provided between the at least one panel member and the cementitious body, preferably in spaces defined by the plurality of spacing members. The insulation and/or sound proofing material may preferably be fire resistant or fireproof.

[0048] In some embodiments, the construction elements may be enveloped or partly enveloped in a waterproof coating during transit and prior to being assembled. For example, the vertical preformed construction elements may preferably include a removable waterproof coating configured to keep the at least one panel member dry until it has been covered by one or more of the horizontal preformed construction elements. Once covered, the waterproof coating may be removed. The waterproof coating may typically include a plastic coating.

[0049] Adjacent construction elements may be connected to one another in any suitable way such that the elements are aligned relative to one another, preferably in a spaced apart arrangement or relationship.

[0050] For example, in some embodiments, each construction element may include a connecting mechanism or part of a connecting mechanism for connecting the element with adjacent elements.

[0051] The connecting mechanism may include a first part associated with an edge of the element and a second part connectable to the first part and associated with an adjacent edge of an adjacent element.

[0052] The parts of the connecting mechanism may respectively include mateable male and female portions that couple together, including threaded connections, bayonet-type connections or interference (snap-fit) connections, for example.

[0053] A first part of the connecting mechanism associated with an edge of the element may include a male formation configured to be at least partially inserted into or coupled with a female formation of a second part of the connecting mechanism associated with an adjacent edge of an adjacent construction element. Conversely, the first part of the connecting mechanism may include the female formation configured to at least partially receive or be coupled with the male formation of the second part of the connecting mechanism.

[0054] In other embodiments, each element may include a coupling member protruding from an edge of the element, preferably an edge of the cementitious body. In preferred such embodiments, each element may include a pair of coupling members extending from opposed edges of the cementitious body. Each coupling member may be adapted to couple with a coupling member provided on an adjacent edge of an adjacent construction element.

[0055] Each coupling member may include at least one opening configured to align with an adjacent coupling member and receive a fastener therethrough. Advantageously, alignment of the coupling members may align the construction element relative to one another, preferably in a spaced apart relationship.

[0056] In some embodiments, at least one coupling member may include an elongate alignment or abutment flange extending transversely across the coupling member. The elongate alignment or abutment flange facilitates positive location of a portion of the coupling member of an adjacent element and in doing so aligns the respective openings of the coupling members to receive a fastener therethrough.

[0057] Generally, the elongate alignment or abutment flange may be attached to or secured relative to the at least one coupling member, preferably welded thereto.

[0058] In some embodiments, the coupling members may include metal plates extending from an edge and the opposed edge of the construction element. The metal plates may be at least partially embedded in the body.

[0059] In some such embodiments, the construction elements may include reinforcing members welded to the metal plates. The reinforcing members may be completely embedded in the body and may be U-shaped as previously described. It is envisaged that the use of hollow sections embedded in the cementitious body may allow for the reinforcing members to be of relatively small diameter in comparison to reinforcing members used when hollow sections are not embedded within the cementitious material.

[0060] In some embodiments of the invention, U-shaped reinforcing members may protrude from opposed ends of the construction element. The U-shaped reinforcing members may be connected to, or otherwise associated with, the U-shaped reinforcing members of an adjacent construction element to assist in connecting adjacent construction elements to one another.

[00611 In some embodiments, at least one of the coupling members protruding from an edge of the element may be a rod and the coupling member protruding from an opposed edge of the element may be a socket extending into the cementitious body. The rod may be at least partially embedded in the body. The socket may include a hollow tube at least partially embedded in the body.

[0062] In some such embodiments, the construction element may further include a bearing plate around the rod at the edge of the body and/or around the socket at the opposed edge of the body.

[0063] In use, the rod of the coupling member on a first construction element may be aligned relative to and be at least partially received in the socket of the coupling member on a second construction element to connect and align the first and second construction elements relative to one another.

[0064] In some particular embodiments, each element may further include a conduit extending between the opposed edges of the cementitious body.

[0065] In some embodiments, the coupling members are I-beams. For example, in some such embodiments, the at least one coupling member protruding from an edge of the element and the at least one coupling member protruding from an opposed edge of the element may be an I-beam embedded in the cementitious body and protruding outwardly from the first edge and the opposed second edge. In other such embodiments, each coupling member may include an I-beam at least partially embedded in the cementitious body and protruding from an adjacent edge.

[0066] In such embodiments, the construction element may further include a bearing plate provided on an end of each said I-beam or on each end of the I-beam.

[0067] As indicated, the construction elements may each include at least one substantially U-shaped bar protruding from an edge of the cementitious body, preferably from at least one pair of opposed edges.

[0068] Suitably, when the construction element is coupled to adjacent construction elements, the at least one substantially U-shaped bar protruding from an edge of the cementitious body may substantially align with a like at least one substantially U-shaped bar protruding from an adjacent edge of the adjacent element.

[0069] The bars may be substantially aligned with a central axis of an edge and/or an opposed edge of the element. Alternatively, the bars may be substantially perpendicular to the central axis of an edge and/or and opposed edge of the element.

[0070] In some embodiments, each construction element may include at least one adjustable bolt for adjusting a position of the construction element relative to other construction elements.

[0071] In a fifth aspect, the invention resides broadly in a system of constructing a multi storey building according to the fourth aspect wherein the preformed construction elements comprise the preformed construction element of the third aspect of the invention.

[0072] According to a sixth aspect of the present invention, there is provided a mould for forming the preformed construction element of the third aspect.

[0073] The moulds may include one or more characteristics or features of the system and construction element as hereinbefore described.

[0074] Generally, each mould will be sized and shaped for the fabrication of preformed construction elements according to engineered specifications specific to the building being constructed.

[0075] Typically, the mould may include a mould for horizontal preformed construction elements and a mould for vertical preformed construction element.

[0076] The mould may be permanent or temporary.

[0077] In some embodiments, the mould may include a casting bed and formwork. In other embodiments, the mould may be formed from just formwork.

[0078] Typically, the mould may include an open or partially open bottom to enable access for a worker to fasten the at least one panel member to the plurality of spacing members prior to concrete or cement being poured atop the adjoined panel member and spacing members.

[0079] In preferred embodiments, the mould may be suspended above a support surface, again to provide access for a worker to the open or partially open bottom of the mould.

[0080] According to a seventh aspect of the present invention, there is provided a preformed construction element formed by the mould of the third aspect.

[0081] Again, the construction element may include one or more characteristics or features of the system, construction element and mould as hereinbefore described.

[0082] Generally, the preformed construction element may include vertical preformed construction elements and horizontal preformed construction elements.

[0083] A method of forming construction elements using the mould will now be described.

[0084] The at least one panel member may first be aligned and placed in the mould. In some embodiments, a protecting layer may be applied between a bottom of the mould and the panel member to prevent any damage to the panel member.

[0085] The plurality of spacing members may then be arranged atop the panel member at spaced intervals.

[0086] The panel member and spacing members may be fastened together with one or more fasteners, preferably a combination of mechanical and chemical fasteners. The mechanical fasteners may preferably be inserted via the open or partially open bottom of the mould such that the head of each mechanical fastener is flush with, or counter-sunk in, the surface of the panel member.

[0087] In some embodiments, insulation and/or sound proofing material may be applied between the spacing members according to engineered specifications.

[0088] Sheeting may then be fastened atop the spacing member preferably with one or more mechanical fasteners to separate and protect the underlying spacing members and panel member from cement or concrete subsequently poured into the mould to form the cementitious body.

[0089] The sheeting advantageously prevents the cement or concrete from mixing and wetting the underlying spacing members, insulation and/or sound proofing material and/or panel member.

[0090] The sheeting may be fastened with one or more mechanical fasteners to the underlying spacing members. Preferably, the heads of the mechanical fasteners may be allowed to protrude to enhance bonding between the adjoined panel member and spacing members and the cementitious body.

[0091] In preferred embodiments, a sealing member or sealant may be applied about each fastener and/or along each edge of the sheeting to prevent the cement or concrete from passing around or through the sheeting.

[0092] Prior to pouring the cement or concrete into the mould, the hollow sections, along with one or more reinforcing members or mesh, coupling members, U-shaped bars, I-beams, bearing plates and/or adjustable bolts may be arranged and positioned within the mould atop the sheeting with supports and/or couplings.

[0093] The cement or concrete may then be poured and allowed to cure in the mould to form the cementitious body and complete the fabrication of the construction element. Preferably, the concrete or cement is a rapid set concrete or cement.

[0094] Once cured, the construction element may be freed from the mould and lifted to a desired location, preferably by one or more cranes.

[0095] Alternatively, the mould containing the construction element may be temporarily lifted to the desired location where the construction element may be freed, and the mould may be returned to its original position. Again, the mould may be lifted and lowered by one or more cranes.

[0096] In some embodiments, each mould may be used to consecutively form a plurality of preformed construction elements. For example, the plurality of preformed construction elements may be formed in a stack build. The mould containing the plurality of preformed construction elements may then be temporarily lifted to a desired location where the plurality of construction elements may be individually freed and positioned. The mould may then be returned to its original position to resume the stack build.

[0097] According to an eighth aspect of the present invention, there is provided a method of constructing a multi-storey building including the following steps: (i) preparing a construction base; (ii) erecting an assembly of vertical preformed construction elements atop the construction base to define one or more walls and/or columns of the building, each element including a cementitious body, one or more hollow sections at least partially embedded within the cementitious body and one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element (iii) connecting at least one panel member to the one or more spacing members; (iv) laying and coupling an assembly of horizontal preformed construction elements atop the assembly of vertical preformed construction elements to define a floor of the building and a construction base of a subsequent storey, each element including a cementitious body and at least one panel member defining at least one surface of the element, said element configured to be joined with adjacent like elements in a side edge to side edge arrangement to define the floor; and (v) repeating steps (ii), (iii) and (iv) until a desired number of storeys of the multi storey building are constructed, wherein, when the construction elements are coupled and/orjoined together relative to one another, the at least one panel member of each said element is arranged relative to other panel members to form internal ceiling and wall surfaces of at least one room of the multi-storey building.

[0098] The method may include one or more characteristics or features of the system and construction elements and moulds as hereinbefore described.

[0099] As indicated, the method includes an initial step of preparing a construction site. Typically, the preparing may include pouring a floor slab. The preparing may further include positioning upright reinforcement members in the slab for the erecting of the assembly of the vertical preformed construction elements.

[00100] The reinforcement members may include upright rebar at least partially embedded into the floor slab.

[00101] Generally, the upright reinforcement members may be positioned to align with the vertical preformed construction elements according to a desired plan or arrangement.

[00102] The preparing may further include establishing one or more casting beds or moulds for the fabrication of the preformed construction elements. A person skilled in the art will appreciate that the number of working moulds will depend on the size of the building being constructed. For example, a construction site may include one, two, three, four, five, six, seven, eight, nine or 10 or more working moulds.

[00103] Generally, the vertical and horizontal preformed construction elements are fabricated according to engineered specifications that may be specific to the building being constructed.

[00104] In some embodiments, the moulds may be suspended moulds so that a worker may have access to an underside of the mould. For example, it is envisaged that a worker will need access to an underside of the mould to fasten the at least one panel member to the plurality of spacing members prior to the cementitious body being poured atop the adjoined panel member and spacing members.

[00105] In some embodiments, the moulds may be transportable or portable. For example, the moulds together with the cast construction elements may be temporarily lifted to a desired storey of a building being constructed, typically via tower crane.

[00106] At step (ii), the method includes erecting the assembly of vertical preformed construction elements to define the one or more walls and/or columns of a storey of the building.

The vertical preformed construction elements are erected by aligning and coupling a lower edge of each element to the protruding upright reinforcement members, preferably via one or more coupling members protruding from a lower edge each construction element.

[00107] The vertical preformed construction elements may further be coupled to another along adjacent side edges, again preferably via one or more coupling elements protruding from one or both side edges.

[00108] Typically, the vertical preformed construction elements may be covered in a waterproof coating to keep the at least one panel member on each element dry until the elements have been covered by the one or more horizontal preformed construction elements according to step (iv). Once covered, the waterproof coating may be removed and reused or recycled.

[00109] In some embodiments, the erected vertical preformed construction elements may be cross-braced or temporarily braced in position. Workers may check that the vertical preformed construction elements are plumb and aligned before fastening them to the floor slab.

[00110] At step (iv), the method includes laying and coupling an assembly of horizontal preformed construction elements atop the erected vertical preformed construction elements to define a floor of the building and a construction base for a subsequent storey.

[00111] The horizontal preformed construction elements are laid by aligning and coupling the elements to one or more upper end edges of the erected vertical preformed construction elements.

[00112] The horizontal preformed construction elements may be directly or indirectly fastened or coupled to the vertical preformed construction elements. In some embodiments, the construction elements may be coupled via one or more coupling members protruding from edges of the vertical construction elements and adapted to couple with corresponding coupling members protruding from the upper end edges of the vertical preformed construction elements.

[00113] Adjacently laid horizontal preformed construction elements may be coupled together in an edge to edge arrangement with one or more lap bars. In some embodiments, a sealant or sealing member be applied along adjoining edges, such as, e.g., a silicone sealant.

[00114] In some embodiments, one or more of the horizontal preformed construction elements may include one or more coupling members or upright reinforcing members protruding upwards from edges or the upward facing surface of the horizontal preformed construction elements for the erection of a subsequent storey of vertical preformed construction elements.

[00115] The one or more coupling members or upright reinforcing members may be at least partially embedded in the cementitious body of the horizontal preformed construction elements.

[00116] Again, the one or more coupling members or upright reinforcement members may be positioned to align with the vertical preformed construction elements of the subsequent storey according to a desired plan or arrangement.

[00117] Once the horizontal preformed construction elements are laid and coupled, the waterproof coating may be removed from the underlying the vertical preformed construction elements as the at least one panel member of each element may now be sheltered by the laid horizontal preformed construction elements.

[00118] Steps (ii), (iii) and (iv) may be repeated until the desired number of storeys of the multi-storey building have been constructed. As indicated, the storeys of the building and, in particular, the construction elements are assembled in a stack build method that enables the multi-storey building to be constructed in a methodical, precise and rapid manner.

[00119] Advantageously, upon completion of construction of each storey of the building, the panel members of the assembled elements are aligned and arranged relative to one another to form internal ceiling and wall surfaces of the storey of the building, preferably of all rooms on the storey constructed. The aligned panel members may then be sealed, sanded and painted according to a desired finish.

[00120] In some embodiments of the invention, a water guiding portion may be provided on one or more of the preformed construction elements. The water guiding portion may be of any suitable form, and may comprise a drain, pipe, conduit, channel or the like, or any suitable combination thereof. It is envisaged that the water guiding portion may be provided in order to provide a pathway for water to flow away from the preformed construction element and/or the building under construction. In particular, the water guiding portion may be provided for situations in which water may collect (for instance overnight during construction) so that the water is able to flow away from the level of the building under construction prior to concrete being poured.

[00121] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[00122] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[00123] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[00124] Figure 1 is an upper perspective and sectional view of a multi-storey building constructed by a system according to an embodiment of the present invention;

[00125] Figures 2A to 2C respectively show sectional views through vertical preformed construction elements according to embodiments of the present invention;

[00126] Figure 3 is a sectional view through a horizontal preformed construction element according to an embodiment of the present invention;

[00127] Figure 4 is a sectional view of the horizontal preformed construction element of Figure 4 coupled together with a like horizontal preformed construction element in a side edge to side edge arrangement;

[00128] Figure 5 is sectional view showing two preformed construction elements coupled relative to one another with a coupling arrangement according to an embodiment of the present invention;

[00129] Figure 6 is a closeup view of the coupling arrangement shown in Figure 5; and

[00130] Figure 7 is a flowchart showing steps in a method of constructing a multi-storey building according to an embodiment of the present invention.

[00131] Figure 8 is a side sectional view of a vertical preformed construction element according to embodiments of the present invention.

[00132] Figure 9 is a cross-sectional view of a vertical preformed construction element according to embodiments of the present invention.

DETAILED DESCRIPTION

[00133] Figure 1 shows a construction system (100) and parts thereof according to an embodiment of the present invention for constructing a multi-storey building (900).

[00134] The system (100) includes a plurality of vertical preformed construction elements

(200) adapted to couple to one another to define the walls (910) of each storey of the building (900) and a plurality of horizontal preformed construction elements (300) configured to be mounted atop the plurality of vertical preformed construction elements (200) and be joined with adjacent like elements (300) to define a floor (920) of the building (900).

[00135] Each vertical and horizontal preformed construction element (200, 300) includes a cementitious body (210, 310), at least one plasterboard panel (220, 320; i.e., at least one panel member) defining a surface of the element (200, 300) and a plurality of spacing members (230, 330) extending therebetween and defining a space (232, 332) for insulation and/or soundproofing material or materials.

[00136] The construction elements (200, 300) are configured to be coupled and/or joined relative to one another to form each storey of the multi-storey building (900).

[00137] Further, when the construction elements (200, 300) are coupled and/or joined relative to one another, the at least one plasterboard panel (220, 320) on each element (200, 300) is arranged relative to other plasterboard panels (220, 320) to form internal ceiling surfaces (922) and wall surfaces (912) of the building (900).

[00138] Figures 2A to 2C show various embodiments of the vertical preformed construction element (200).

[00139] As shown, each element (200) is in the form of a panel having a substantially rectangular shape.

[00140] Each element (200) includes a pair opposed surfaces, a lower end edge (not visible), an opposed upper end edge (202) and a pair of opposed side edges (204). The opposed surfaces include an inward facing surface (206) and an opposed outward facing surface (208).

[00141] In Figure 2A the plasterboard panel (220) extends entirely across the inward facing surface (206) to facilitate the formation of wall surfaces (912; not shown) when the elements (200) are coupled and/or joined relative to one another in a side edge (204) to side edge (204) arrangement.

[00142] In Figure 2B both of the opposed surfaces include a plasterboard panel (220) extending entirely across each surface. The provision of plasterboard panels (220) across each of the surfaces facilitates the forming of internal dividing walls in a building, for example.

[00143] In Figure 2C the element (200) includes plasterboard panel (220) extending entirely about a periphery of the element (200) to facilitate the formation of columns in a building (900; not shown) for example.

[00144] Referring again to Figures 2A to 2C, each element (200) includes a cementitious body (210), which is cast in a mould together with other components of the element (200).

[00145] The body (210) includes reinforcing members at least partially embedded in the body (210; i.e., rebar)

[00146] As indicated above, the plasterboard panel(s) (220) are indirectly fastened to the cementitious body (220) via the plurality of spacing member (230) extending therebetween. The spacing members (230) are wooden battens.

[00147] Generally, the plasterboard panel(s) (220) are fastened to the spacing members (230) with mechanical fasteners and adhesive and the cementitious body is poured in a mould at least partly about the adjoined plasterboard panel(s) (220) and spacing members (230).

[00148] The element (200) further includes waterproof sheeting (240) extending between the spacing members (230) and the body (210) to prevent wetting of the plasterboard panel(s) (220) and spacing members (230) when the body (210) is cast. Typically, the sheeting (240) is fastened to the spacing members (230) with mechanical fasteners. The head (242) of each fastener protrudes out from the sheeting (240) to facilitate bonding between the body (210) and the adjoined plasterboard panel(s) (220) and spacing members (230).

[00149] Once fabricated, the construction elements (200) are enveloped or partly enveloped in a waterproof coating during transit and prior to being assembled to protect the plasterboard panels (220) from being dampened or wet.

[00150] Figure 3 shows an embodiment of a horizontal preformed construction element (300).

[00151] Like the vertical preformed construction elements, the element (300) is in the form of a panel having a substantially rectangular shape.

[00152] Each element (300) includes a pair opposed surfaces, a pair of end edges (302) and a pair of opposed side edges (304). The opposed surfaces include a downward facing surface (306) and an opposed upward facing surface (308).

[00153] The plasterboard panel (320) extends entirely across the downward facing surface to facilitate formation of a ceiling surface (922; not shown) when the element (300) is coupled and/or joined relative to other elements in a side edge (304) to side edge (304) arrangement as shown in Figure 4.

[00154] Again like the vertical preformed construction elements, each element (300) includes a cementitious body (310), which is cast in a mould together with other components of the element (300).

[00155] The body (310) includes reinforcing members, i.e., rebar, at least partially embedded in the body (310).

[00156] As indicated above, the plasterboard panel (320) is indirectly fastened to the cementitious body (320) via the plurality of spacing member (330) extending therebetween. The spacing members (330) are wooden battens.

[00157] The plasterboard panel (320) is fastened to the spacing members (330) with mechanical fasteners and adhesive and the cementitious body is poured in a mould at least partly about the adjoined plasterboard panel (320) and spacing members (330).

[00158] Again, the element (300) includes waterproof sheeting (340) extending between the spacing members (330) and the body (310) to prevent wetting of the plasterboard panel (320) and spacing members (330) when the body (310) is cast. The sheeting (340) is fastened to the spacing members (330) with mechanical fasteners. The head (342) of each fastener protrudes out from the sheeting (340) to facilitate bonding between the body (310) and the adjoined plasterboard panel (320) and spacing members (330).

[00159] Referring to Figure 5, the construction elements (200, 300) are connected together via a coupling arrangement including a pair of coupling members (610) protruding from adjacent edges of the adjacent elements (200, 300).

[00160] Referring to Figure 6, each coupling member (610) includes one opening (612) configured to align with the opening (612A) in the adjacent coupling member (610A) and receive a fastener (620) therethrough. Advantageously, alignment of the coupling members (610, 61OA) aligns the construction elements (200, 300; not shown) relative to one another in a spaced apart relationship.

[00161] As shown, some coupling members (610) further includes an elongate alignment or abutment flange (630) extending transversely across the coupling member (610). The elongate alignment or abutment flange (630) facilitates positive location of a portion of the coupling member (610A) of the adjacent element (not shown) and in doing so aligns the respective openings (612, 612A) of the coupling members (610, 610A) to receive the fastener (620) therethrough.

[00162] Referring again to Figure 5, the coupling members (610) are partially embedded in the body (210, 310) of the elements (200, 300) and typically connected to reinforcing members fully embedded in the body (210, 310).

[00163] The construction elements (200, 300) further each include substantially U-shaped bars (650) protruding from edges of the cementitious body (210, 310).

[00164] As shown, when the construction element (200, 300) is coupled to adjacent construction elements (200, 300), the substantially U-shaped bars (650) protruding from each element (200, 300) substantially align to assist in alignment and spacing of the elements (200, 300) relative to one another.

[00165] Referring back to Figure 4, the horizontal preformed construction elements (300) are laid by aligning and coupling the elements (300) to one or more upper end edges of the erected vertical preformed construction elements (200; not shown).

[00166] The horizontal preformed construction elements (300) are coupled together in a side edge (304) to side edge (304) arrangement with one or more lap bars (350). A sealant or sealing member is applied along adjoining side edges (304). The lap bars (350) are received and fastened with one or more mechanical fasteners (not shown) in recessed grooves (309) provided on opposite sides of the upward facing surface (308) of each element (300).

[00167] A method (700) of constructing a multi-storey building (900) as shown in Figure 1 is now described with reference to Figure 7.

[00168] At step 710, a construction base is prepared, including pouring a floor slab or foundation. The preparing further includes upright reinforcement members in the slab for erection of the assembly of the vertical preformed construction elements (200).

[00169] The reinforcement members include upright rebar at least partially embedded into the floor slab or foundation.

[00170] The upright reinforcement members are positioned to align with the vertical preformed construction elements (200) according to a desired plan or arrangement.

[00171] The preparing further includes establishing one or more casting beds or moulds for the fabrication of the preformed construction elements (200, 300). A person skilled in the art will appreciate that the number of working moulds will depend on the size of the building (900) being constructed.

[00172] Generally, the vertical and horizontal preformed construction elements (200, 300) are fabricated according to engineered specifications that may be specific to the building (900) being constructed.

[00173] The moulds are suspended moulds so that a worker may have access to an underside of the mould. For example, a worker will need access to an underside of the mould to fasten the plasterboard panel (220, 320) to the spacing members (230, 330) prior to the cementitious body (210, 310) being poured atop the adjoined plasterboard panel (220, 330) and spacing members (230, 330).

[00174] Further, the moulds are transportable or portable. For example, the moulds together with the cast construction elements (200, 300) are temporarily lifted to a desired storey of the building (900) being constructed via tower crane.

[00175] At step 720, the vertical preformed construction elements (200) are erected to define the walls (910) of the building (900). The vertical preformed construction elements (200) are erected by aligning and coupling a lower edge of each element (200) to the protruding upright reinforcement members via one or more coupling members (610) protruding from edges of each construction element (200).

[00176] The elements (200) are further coupled to one another along adjacent side edges (204) via the coupling members (610).

[00177] The vertical preformed construction elements (200) are then covered in a waterproof coating to keep the plasterboard panel (220) on each element (200) dry.

[00178] The erected vertical preformed construction elements (200) are cross-braced or temporarily braced in position. Workers may check that the vertical preformed construction elements (200) are plumb and aligned before fastening them to the floor slab.

[00179] At step 730, the horizontal preformed construction elements (300) are laid and coupled atop the erected vertical preformed construction elements (200) to define a floor (920) of the building (900) and a construction base for a subsequent storey.

[00180] The horizontal preformed construction elements (300) are laid by aligning and coupling the elements (300) to one or more upper end edges (202) of the erected vertical preformed construction elements (200).

[00181] Further, the horizontal preformed construction elements (300) are coupled together in a side edge (304) to side edge (304) arrangement with one or more lap bars (350). A sealant or sealing member is applied along adjoining edges.

[00182] Once the horizontal preformed construction elements (300) are laid and coupled, the waterproof coating is removed from the underlying the vertical preformed construction elements (200) as the plasterboard panels (220) of each element (200) is now sheltered by the laid horizontal preformed construction elements (300).

[00183] At step 740, steps 720 and 730 are consecutively repeated until the desired number of storeys of the multi-storey building (900) have been constructed.

[00184] Upon completion of construction of each storey of the building (900), the plasterboard panels (220, 320) of the assembled elements (200, 300) form internal ceiling surfaces (922) and wall surfaces (912) of the storey of the building (900). The plasterboard panels (220, 320) are ready to be sealed, sanded and painted according to a desired finish.

[00185] Figure 8 is a side sectional view of a vertical preformed construction element 1000 according to embodiments of the present invention. The construction element includes a plurality of rectangular hollow sections 1001 positioned end on end within the element 1000. The hollow sections 1001 are embedded within a cementitious body 1002. Spacing members 1003 in the form of battens are partially embedded within the cementitious material 1002 to form a portion of the outer surface of the element 1000.

[00186] Apertures 1004 are provided in the hollow sections 1001 to both allow the flow of wet cementitious material therethrough during the forming of the element 1000 and to allow reinforcing members (not shown in this Figure) to pass through the apertures 1004.

[00187] A coupling member 1005 extends along the length of the element 1000 and protrudes from opposed ends thereof. The coupling member 1005 may be connected to the coupling member 1005'of an adjacent element 1000'to form levels or floors within the structure being constructed. Typically, coupling members 1005, 1005' are connected using mechanical fasteners, such as, but not limited to, bolts, and in particularly high tensile bolts.

[00188] U-bars 1006 also extend outwardly from opposed ends of the element 1000, and the U-bars 1006 projecting from adjacent elements 1000, 1000' may also be joined together in order to connect the adjacent elements 1000, 1000' to one another.

[00189] Once adjacent elements 1000, 1000' are connected to one another concrete 1007 is poured into the gap between the cementitious bodies 1002 of adjacent elements 1000, 1000'. In this way, a floor may be formed between adjacent levels or storeys within the structure.

[00190] Figure 9 is a cross-sectional view of a vertical preformed construction element 1000 according to embodiments of the present invention. In this Figure, the rectangular hollow section 1001 may be seen embedded within the cementitious body 1002, with the coupling member 1005 positioned within the rectangular hollow section 1001 and surrounded by the cementitious body 1002.

[00191] Reinforcing members 1008 may be seen passed through apertures (obscured) in the hollow section 1001.

[00192] Spacing members 1003 are partially embedded within the cementitious body 1002 and form part of the outer surface of the element 1000. The spacing members 1003 are configured to allow the connection of a panel member (not shown in this Figure) thereto.

[00193] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises'and 'comprise'include each of the stated integers but does not exclude the inclusion of one or more further integers.

[00194] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[00195] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. A system of constructing a multi-storey building, said system including: a plurality of vertical preformed construction elements configured to define one or more walls and/or columns of the building, each element including a cementitious body, one or more hollow sections at least partially embedded within the cementitious body, one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element, each said element adapted to couple with adjacent construction elements to define the one or more walls and/or columns; and wherein at least one panel member is connected to the one or more spacing members, a plurality of horizontal preformed construction elements configured to be mounted atop the plurality of vertical preformed construction elements to define a floor of the building, each element including a cementitious body and at least one panel member defining a surface of the element, each said element configured to be joined with adjacent like elements in an edge to edge arrangement to define the floor, wherein said construction elements are configured to be coupled and/or joined relative to one another to form at least one storey of the multi-storey building, and wherein when the construction elements are coupled and/or joined relative to one another, the at least one panel member on each said element is arranged relative to other panel members to form internal ceiling and wall surfaces of at least one room of the multistorey building.

2. A preformed construction element, said element including: a cementitious body; one or more hollow sections at least partially embedded within the cementitious body;and one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element, wherein the one or more spacing members are configured to allow for the connection of a panel member thereto

3. A preformed construction element according to claim 2 wherein each of the preformed construction elements includes a pair of opposed surfaces extending substantially parallel to one another, a pair of opposed side edges and a pair of opposed end edges.

4. A preformed construction element according to claim 2 or claim 3 wherein the panel member extends across an entire surface of the preformed construction element to facilitate the forming of ceiling and/or wall surfaces when the performed constructions elements are coupled and/or joined relative to one another

5. A preformed construction element according to any one of claims 2 to 4 wherein the preformed construction element includes at least one coupling member adapted to couple with a like coupling member provided on an adjacent construction element to couple the preformed construction elements together.

6. A preformed construction element according to any one of claims 2 to 5 wherein the cementitious body includes one or more reinforcing members at least partially embedded therein.

7. A preformed construction element according to any one of claims 2 to 6 wherein the at least one panel member includes internal cladding or plasterboard.

8. A preformed construction element according to any one of claims 2 to 7 wherein each of the plurality of spacing members comprise an elongate member that transversely extends across and between the body and the panel member.

9. A preformed construction element according to any one of claims 2 to 8 wherein the element further includes sheeting extending between the spacing members and the cementitious body to prevent wetting of the at least one panel member when the body is cast.

10. A preformed construction element according to claim 9 wherein the sheeting includes waterproof or water-resistant sheeting.

11. A preformed construction element according to any one of claims 2 to 10 wherein the element further includes insulation and/or sound proofing material provided between the at least one panel member and the cementitious body.

12. A preformed construction element according to any one of claims 2 to 11 wherein the element includes a connecting mechanism or part of a connecting mechanism for connecting the element with adjacent elements.

13. A preformed construction element according to claim 12 wherein the connecting mechanism includes a first part associated with an edge of the element and a second part connectable to the first part and associated with an adjacent edge of an adjacent element.

14. A preformed construction element according to claim 13 where in the first part and the second part include mateable male and female portions that couple together, including threaded connections and/or bayonet-type connections or interference (snap-fit) connections.

15. A preformed construction element according to any one of claims 2 to 14 wherein the element comprises a coupling member protruding from an edge of the element, the coupling member being adapted to couple with a coupling member provided on an adjacent edge of an adjacent construction element.

16. A preformed construction element according to any one of claims 2 to 15 wherein the hollow sections comprise rectangular hollow sections.

17. A preformed construction element according to any one of claims 2 to 16 wherein the hollow sections are positioned substantially co-axially with one another.

18. A system of constructing a multi-storey building according to claim 1, wherein the preformed construction elements comprise the preformed construction elements of any one of claims 2 to 17.

19. A mould for forming the preformed construction element of any one of claims 2 to 17.

20. A system according to claim 1 wherein adjacently laid horizontal preformed construction elements are coupled together in an edge to edge arrangement with one or more lap bars.

21. A method of constructing a multi-storey building including the following steps: (i) preparing a construction base; (ii) erecting an assembly of vertical preformed construction elements atop the construction base to define one or more walls and/or columns of the building, each element including a cementitious body, one or more hollow sections at least partially embedded within the cementitious body and one or more spacing members partially embedded in the cementitious body such that the one or more spacing members form an outer surface of the element (iii) connecting at least one panel member to the one or more spacing members; (iv) laying and coupling an assembly of horizontal preformed construction elements atop the assembly of vertical preformed construction elements to define a floor of the building and a construction base of a subsequent storey, each element including a cementitious body and at least one panel member defining at least one surface of the element, said element configured to be joined with adjacent like elements in a side edge to side edge arrangement to define the floor; and (v) repeating steps (ii), (iii) and (iv) until a desired number of storeys of the multi storey building are constructed, wherein, when the construction elements are coupled and/orjoined together relative to one another, the at least one panel member of each said element is arranged relative to other panel members to form internal ceiling and wall surfaces of at least one room of the multi-storey building.

610 100 202 200 900

210 910 220

230 912 232

330 1/7

332

920 320

922

310 304 350

300

Figure 1